agco 925x to lexion - headsight · wiring and diagrams 27 ... • qp0-ca12-31a • this harness is...
TRANSCRIPT
Conversion Manual09040406a
AGCO 925XTOLEXION
HEADSIGHT.COM | 574.546.5022
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Copyright Headsight, Inc. 2018
About Headsight
Headsight Contact InfoHeadsight, Inc. 4845 3B Road Bremen, IN 46506 Phone: 574-546-5022 Fax: 574-546-5760 Email: [email protected] Web: www.headsight.com
Technical AssistancePhone: 574-220-5511
About this Manual
How to use this manualThe instructions in this manual are in the order that they should be completed for new installations. Complete all applicable instructions in each section before proceeding. Note that some sections are labeled to indicate they only apply to certain machines or applications. An index is available in the front of the manual to help find technical information for previously installed systems.
This icon designates information of which you should take note.
This icon indicates a special tool needed for a given task.
This icon designates an important instruction.
DisclaimersHeadsight®, Horizon®, Pinpoint®, Insight®, Foresight®, Feathersight® Truesense™ and Truesight® are trademarks of Headsight, Inc. All other trademarks are property of their respective owners.
SuggestionsIf you have any suggestions to improve this manual please call 574-546-5022 or email [email protected].
Headsight’s products are protected by one or more of the following US Patents 6202395, 6833299, 7310931, 7647753 and other patents pending.
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Table of ContentsAbout Headsight ��������������������������������������������������������������������������������������������� iAbout this Manual ������������������������������������������������������������������������������������������� iInstallation �������������������������������������������������������������������������������������������������� 1
Components ����������������������������������������������������������������������������������������������� 2Multilink and Valve Mounting �������������������������������������������������������������������������� 4Insight Box Mounting ������������������������������������������������������������������������������������ 4Header Adapter Harness Mounting ������������������������������������������������������������������� 5Multilink Connection ������������������������������������������������������������������������������������ 5Reel Enable Connection ��������������������������������������������������������������������������������� 6Solenoid Connection ������������������������������������������������������������������������������������ 6Hydraflex Cab Controller �������������������������������������������������������������������������������� 6Reel Select Solenoid ������������������������������������������������������������������������������������� 7Reel Select Harness �������������������������������������������������������������������������������������� 7Pressure Shift Module ����������������������������������������������������������������������������������� 8Reel F/A Switch Kit ��������������������������������������������������������������������������������������� 9Feeder Harness ������������������������������������������������������������������������������������������� 9Pressure Sensor Bypass Harness (4/500 Only) ����������������������������������������������������� 9
Calibration ��������������������������������������������������������������������������������������������������10Header Sensor Calibration �����������������������������������������������������������������������������10Insight Calibration ��������������������������������������������������������������������������������������11
Initialize Insight ���������������������������������������������������������������������������������������11Calibrate Insight ���������������������������������������������������������������������������������������11
Combine Calibration ������������������������������������������������������������������������������������12Calibration: 4/500 Series, Flex Headers �����������������������������������������������������������12Calibration: 6/700 Series ����������������������������������������������������������������������������13
Settings ������������������������������������������������������������������������������������������������������14Insight Settings ������������������������������������������������������������������������������������������14
Tilt Sensitivity �����������������������������������������������������������������������������������������14Tilt Balance ���������������������������������������������������������������������������������������������14
Combine Settings ����������������������������������������������������������������������������������������154/500 Combines ���������������������������������������������������������������������������������������156/700 Series ��������������������������������������������������������������������������������������������16
Operation ���������������������������������������������������������������������������������������������������17AHC Operation: All Combines��������������������������������������������������������������������������17Adjusting Float Pressure �������������������������������������������������������������������������������18
Overview ����������������������������������������������������������������������������������������������������19Insight® Navigation ��������������������������������������������������������������������������������������19
How to Navigate ����������������������������������������������������������������������������������������19Meaning of Status Light �������������������������������������������������������������������������������19Screen Contrast Adjustment �������������������������������������������������������������������������19Resetting Insight® to Defaults �����������������������������������������������������������������������20Updating Insight® Software with USB Drive �������������������������������������������������������20
Advanced Information ������������������������������������������������������������������������������������21
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Theory of Operation ������������������������������������������������������������������������������������21Basic Requirements �������������������������������������������������������������������������������������21Reading Voltages ����������������������������������������������������������������������������������������22
Before You Start ���������������������������������������������������������������������������������������22On the Insight® Box : Sensor Voltages ��������������������������������������������������������������22On the Insight® Box : Output Voltages ��������������������������������������������������������������22
Reading Voltages: Combine ����������������������������������������������������������������������������2312V Power Test ������������������������������������������������������������������������������������������23600 & 700 Series Calibration Issues ������������������������������������������������������������������24
Symptom: �����������������������������������������������������������������������������������������������24Cause: ���������������������������������������������������������������������������������������������������24Solutions: �����������������������������������������������������������������������������������������������24
12V Power Wire Installation ���������������������������������������������������������������������������25Wiring and Diagrams �����������������������������������������������������������������������������������27
Header Adapter Harness �����������������������������������������������������������������������������27Feeder Harness ����������������������������������������������������������������������������������������28Reel Select Harness �����������������������������������������������������������������������������������29Multilink ������������������������������������������������������������������������������������������������30Header Adapter Schematic (Part 1) ����������������������������������������������������������������31Header Adapter Schematic (Part 2) ����������������������������������������������������������������32Feeder Adapter Schematic: ��������������������������������������������������������������������������33Multilink Diagram (Part 1)���������������������������������������������������������������������������34Multilink Diagram (Part 2)���������������������������������������������������������������������������35Header Multilink Mechanical ������������������������������������������������������������������������36Reel Select Schematic: �������������������������������������������������������������������������������37
Diagnostics �������������������������������������������������������������������������������������������������38Troubleshooting by Symptom �������������������������������������������������������������������������38Reel/Flex Diagnostics �����������������������������������������������������������������������������������42Troubleshooting by Insight® Error Codes �����������������������������������������������������������44
Parts ���������������������������������������������������������������������������������������������������������51STATEMENT OF LIMITED WARRANTY �����������������������������������������������������������������52
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Installation
Installation
Before working under header always:
1. Perform all combine and header manufacturer safety precautions for servicing header.
2. Insert stop to prevent movement of header.
3. Turn off combine and remove key from ignition.
4. Set combine parking brake.
5. Disconnect all drive shafts from the header.
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Installation
Components
1. Multilink• CA500MLHYD• Required to allow connection to the combine
2. Hydraulics, Dual Valve Assm. kit• HT9002• Required to control the hydraulic functions on the
header to the combine. See valve-specific manual. • Also Includes the Reel Flow fittings
3. Insight• INSIGHT• Converts the AHC system on the header to the
Lexion combine.
4. Header Adapter Harness• QP0-CA12-31A• This harness is installed on the Header, between
the Insight, Lexion multilink, valve assm, and the OEM header connection. For connector details, see “Wiring” in the Appendix
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Installation
5. Feeder Harness• HT9870-FH • This harness is installed on the combine, between
the cab and the Multilink. Connects to the Cab Controller(s) and the Header Adapter. For connector details See “Wiring” in the Appendix
6. Hydraflex Cab Control• HT9993• Mounts in the cab to display and adjust the Flex
Pressure.
7. Reel Select Update• 08100147 NC solenoid spool
• Replaces NO valve on header • HT9863-RS harness
8. Pressure shift module• HT9219
9. Reel F/A Switch Kit• Not shown• See Switch Kit Installation Manual
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Installation
Make sure the cable routing is done so no wiring can bind or pinch. Tie up all loose cabling. Properly installed wiring is the most critical aspect of a trouble-free installation. For harness details, see Wiring.
Multilink and Valve Mounting
1. Mount the Headsight Multilink assembly on the header. • Shown with combine connected• Adjust mounting position to best fit your header
2. See the Specific Installation Guide for the Dual Valve assembly for details on the next steps.
3. Mount the hydraulic valve assembly to the head.
4. Route the pressure and tank hoses from the valves to the multilink.
5. Disconnect the smaller hoses from the OEM Header Single point and connect them to the valve assembly.
6. Install the Reel Flow couplings into the Multilink and connect the Reel Drive hoses. • Fitting adapters may be needed
Insight Box Mounting
1. Hold Insight unit (or mounting bracket if supplied) at rear of header near the Multilink and feederhouse electrical connection on combine and mark mounting hole locations.
2. Drill mounting holes using ¼" drill bit.
3. Secure box to header. • Use provided tie straps or ¼" bolts• Box must be within reach of the header electrical
connector and the Multilink
4. Connect the 24 pin connector on the adapter Header harness to the Insight box using an Allen wrench.
If Insight Box does not power up after completing full installation section, check that Y401 is connected to correct port on multilink, and see Advanced Info, 12V Power Test.
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Installation
Header Adapter Harness Mounting
1. Remove the C clip holding the OEM header electrical connector in the AGCO single-point plate. Remove the connector from the plate.
2. Press the connector into Y502 on the QP0-CA12-31A adapter harness.
3. Slip the HT2259 bracket over the connection and secure with zip ties.
4. Tie Y424 so it is easy to connect during header hookup.
Multilink Connection
1. Connect Insight™ header harness to header side of multilink block.• The plug marked Y410 should connect to
receptacle VS1• The plug marked Y401 should connect to
receptacle VS2• Make sure Y424 (16 pin Round) is tied so that it is
easily accessible when connecting/disconnecting the header
2. Connect Y111 and Y112 (Lights) together.
3. Connect Y407 and Y408 (Valve Functions) together.
4. Tie Y424 so it is easy to connect during header hookup.
VS1
VS2
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Installation
Reel Enable Connection
This step is only applicable to Multilink assemblies provided by Headsight®.
1. To Enable reel drive flow, connect the mating 1p Weatherpack connectors, Y517 & Y518.
Solenoid Connection
1. There are two sets of solenoid connections, Reel Lift & Reel F/A (shown). Follow the steps below to correctly attach them.• See the Dual Valve Installation manual for solenoid
identification• Connect Y411 to the Reel Lift Solenoid• Connect Y412 to the Reel Lower Solenoid• Connect Y413 to the Reel Fore Solenoid• Connect Y414 to the Reel Aft Solenoid• If any function acts in reverse, swap the connections
at the solenoids.
Hydraflex Cab Controller
1. Use the included suction mount to attach the Control to the right cab window above the console. • Place in an easy to see and reach location
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Installation
Reel Select Solenoid
1. Do the entire previous sections of installation.
2. Release all pressure from the reel & flex control circuit, if not already done.
3. Disconnect the OEM wiring connector from the Reel Selector Solenoid.
4. Remove the solenoid coil from the valve spool.
5. Carefully remove the OEM N.O. valve spool from the valve block and replace it with the included N.C. valve spool.
6. Reinstall the Reel Select solenoid on the new N.C. valve spool.
7. Do not reconnect the OEM wiring; see Reel Select Harness below.
8. Store the OEM N.O. valve spool for re-installation during trade-in.
Reel Select Harness
1. Connect Y540 to the reel select solenoid.
2. Connect Y541 to the OEM reel select connector.
3. Route Y539 across the header with the other wiring and piping to the left side of the feeder. • To ease access, you may wish to remove the shields
above the frame rail on the header from the left side of the feeder to the right end of the header
FRONTBACK
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Calibration
4. Connect Y539 to Y538 on the header adapter harness.
5. Coil up any excess under shields and reinstall all shields.
Pressure Shift Module
1. Disconnect the plug from the OEM pressure sensor on the diverter valve assembly.
2. Connect Y522 to the pressure sensor.
3. Connect Y523 to the OEM connector.
This module increases the pressure “signal” by about 500psi, so the Flex Controller will display higher than actual pressure. This is necessary to adjust the Dynaflex pressure sensor into the right range for the display.
FRONTBACK
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Calibration
Reel F/A Switch Kit
1. Follow the instructions in the F/A Switch Kit Installation manual to mount and connect the switch for Reel F/A.
2. Connect the included power wire inside the console.• Connect the red wire to a 30A capable 12V source--
battery or switched• Connect the black wire to a clean frame ground bolt
3. Coil the harness in the cab to connect to the Feeder Harness installed below.
Feeder Harness
1. Open the Right hand Console inside the cab (bolt under Cebis monitor.)
2. Route the 12 pin connectors Y225 and Y534 of the Feeder Harness up into the cab using the access point on the floor of the console housing.
3. Route the harness across under the cab and down the Multilink Pigtail.
4. Making sure to leave sufficient wire to connect to the header harness, cable tie the feeder harness up to the multilink pigtail and across the cab.
5. Route the feeder harness Y225 and Y534 out the back of the console and around to connect to the Cab Controls.
6. Connect Y225 into the Hydraflex controller firmly (until latch clicks.)
7. Connect Y534 to the switch kit harness (coil excess wire under console.)
8. Attach the Feeder Harness Y423 to Y424 at the Header Adapter.
Pressure Sensor Bypass Harness (4/500 Only)
Many Headsight systems require the use of a Pressure Bypass Harness. This is needed for OFF-GROUND height control only. When operating in Flex Mode, this wire does not need to be installed. If already installed, the 2 pin jumper plug must be installed in Headsight pressure sensor harness when Insight™ is disconnected, such as when a flex head is being operated.
1. Do not use the pressure bypass with flex headers operating “On-Ground” in Flex mode.
2. If the Pressure Bypass is installed for another application, make sure the Y402J jumper plug is installed when operating in flex mode.
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Calibration
Calibration
Header Sensor Calibration
The Dynaflex uses up to 6 height sensors for active height control. These sensors may not be factory calibrated. Proper operation of the header requires that these sensors be set correctly. • Failure to properly adjust these sensors could result in severe damage to the header!• A Sensor Tester and adapter are included to simplify this process.• The sensors must be calibrated before using the header, and once yearly thereafter.
1. Before starting, test the Sensor tester.• Using a scrap wire, short the Pink and White wires together in the blue tester plug• The tester should read 4.9-5.1V• If reading is < 4.8V, change the battery
2. Connect the Agco Adapter to the blue connector.
3. Lower the header all the way down on a level surface, preferably flat concrete.
4. Disconnect the OEM harness from each sensor.
5. Connect the Sensor Tester adapter to the sensor.
6. Adjust all sensors so they read between 1.0 and 1.2V.• Loosen 2 bolts and rotate sensor until desired voltage is reached• Tighten bolts
7. Reconnect the OEM harnesses to all the sensors.
Note: The sensor tester can be used to test any 3 wire potentiometer or 5V analog sensor with appropriate adapters: Call Headsight® for more information.
11
Calibration
Insight Calibration
Initialize Insight
These steps must be performed the first time the Insight box is powered up and each time it is reset. They do not need to be redone each time the Insight box is calibrated.
Refer to “Insight Overview” for basic Insight operation information.
8. Connect all wiring to the Insight box and combine.
9. Start the combine.
10. Chose “English”, “Lexion”.
11. For ALL flex head conversions, choose Lexion 600/700 combine (even if you are running a 400 or 500 series.)
12. Choose the number of height sensors.• For AGCO 925x flex, choose 2 (OEM module on head outputs only 2 signals to Insight)
Calibrate Insight
When you initialize Insight, you will be led directly to this calibration routine. If you wish to recalibrate at any other time – choose “>>Perform Calibration” on the Insight main menu.
1. Park the combine on a level and smooth surface.
2. Release the flex pressure so cutterbar is hanging fully down.
3. Follow on-screen instructions.• “Raise Header” - Press Enter
• Raise the head high enough that NO sensors touch the ground.• Voltages should typically be in the 3.0-4.5V range
• “Lower Header” - Press Enter• Lower the head ALL the way down onto the skids• Voltages should typically be in the 0.5-2.0V range• Each sensor must change at least 1.0V
12
Calibration
Combine Calibration
Calibration: 4/500 Series, Flex Headers
This section applies to ALL 400 and 500 combines when operating a Flex Head in Flex mode.
1. Start Combine.
2. Make sure that the Headsight Bypass harness is either not installed, or is disconnected from the header harness and has the Y402J jumper in place.
3. Adjust the CAC setting.
• Choose on the harvest display – Press OK• Choose “Header” – Press OK• Choose “Sensitivity CAC” – Press OK• Adjust setting as suggested for a flex platform in the Lexion Owner’s Manual. Increasing the setting
should weight height over tilt
4. Raise head almost up, and speed up motor.
5. Choose “Cutt. Height Limits” – Press OK.
6. Follow on-screen instructions. (If head drops too fast, see Combine Settings. • Raise header• Lower header
7. After calibration, the right bar graph (feeder position) should read “empty” to “full” as the head is moved full stroke.
8. After calibration, the left graph should read:• Nearly “empty” with the head all the way down hard• Nearly “full” as the cutterbar just leaves the ground
9. If the graphs operate as suggested, the header sensors are working properly and the calibration is good.
13
Calibration
Calibration: 6/700 Series
To insure a proper calibration, make sure your combine has the latest Lexion recommended software and the feeder to header latching mechanism is tight with minimal play. See Appendix for more information.
1. Start Combine. 2. Use the Scroll knob and ESC to navigate the menus as
shown:3. Get to the HHC “Learning End Stops”
• Choose on the main display – Press the Scroll knob to OK
• Choose – Press OK
• Choose – Press OK
• Choose – Press OK
4. The screen should read “Start learning procedure with “OK”.5. Follow on-screen instructions. 6. You may also wish to calibrate other relevant items such as “Lateral Float End Stops” and “Reel End
Stops”. See your Lexion Owners Manual.7. Also adjust working position to about 50%.
8. After calibration, the right bar graph (feeder position) should read 0-100 as the head is moved full stroke.
9. After calibration, the left graph should read:• 0 with the head all the way down hard• 50 as the header frame begins to lift off the ground • 100 as the cutterbar just leaves the ground• 0-49 is the header lift pressure• 50-100 is the header AHC sensors
10. If the numbers on the graphs are close to this, the calibration is good.
OK ESC
14
Settings
Settings
Insight Settings
Tilt Sensitivity
1. To change this setting go to >>Settings>>Tilt Sensitivity in the Insight™ box.• Default setting is 50.
2. Adjust combine Tilt Sensitivity first (when available.)
3. If the head is to jumpy from side to side:• Decrease sensitivity
4. If you would like the head to be more responsive:• Increase sensitivity
5. Press Enter to save value.
Tilt Balance
1. To change this setting go to >>Settings>>Tilt Balance in the Insight™ box.• Default setting is 100
2. Make certain ALL other possible causes of head running out of level are eliminated first:• Insight/sensors not calibrated on flat level surface• Combine not calibrated on same surface as Insight• Cutterbar pressure fully released during calibration• Header float not equal across head. Cutterbar should move the same travel at both ends
3. If the head will still not run level:• Increase value to tilt head to right• Decrease value to tilt head to left• Press Enter to save value
4. This setting must be reset to 100 every time before doing a combine header calibration.
15
Settings
Combine Settings
Properly setting the combine is essential to having responsive header control. You should become very familiar with these steps.
4/500 Combines
1. Perform “Cutting Height Limits” calibration before attempting fine tuning.
2. Set CAC setting.• For On-Ground operation of a flex head, do not install the Pressure Bypass
• Adjust the CAC to an appropriate setting exactly as if you were operating a Lexion header (see Lexion Owner’s Manual)
• Choose on the harvest display – Press OK• Choose “Header” – Press OK• Choose “Sensitivity CAC” – Press OK
• Adjust setting as suggested for a flex platform in the Lexion Owner’s Manual. Increasing the setting should weight height over tilt
• Always redo “Cutting Height Limits” calibration after changing Sensitivity CAC. Insight must be in >>Setup >>Combine Cal Mode
4/500 High Speed Drop Rate
1. Use the high speed drop rate valve adjustment knob on the main valve block.• Turn OUT (counterclockwise) to slow down, IN (CW)
to speed up• If the speed is to fast – hunting will occur• If the speed is to slow – the system will not be
responsive enough
2. Common range is 8-10 seconds from header full up to full down in automatic mode.
16
Settings
6/700 Series
Set the high speed drop rate as high as you like without causing head “hunting”. If the head “hunts”, decrease the drop rate. You may need to set this before calibration if it is too fast.
1. Perform “Learning End Stops” calibration before attempting fine tuning.
2. Start Combine.
3. Use the Scroll knob and ESC to navigate the menus as shown:
4. Get to the HHC “Sensitivity CAC”.
• Choose on the main display – Press the Scroll knob to OK
• Choose – Press OK
• Choose – Press OK
• Choose – Press OK
5. All Settings have a range of -50 to +50.
6. “Cutting Height Adjustment” is actually height sensitivity. It should be adjusted just below the point the head will “hunt”.
7. Adjust the “Lateral leveling” to increase/decrease lateral response. It should be adjusted just below the point the head will “rock” side to side.
8. Set “fast manual raising” to 5-6 seconds Full down to full up.
9. Set “fast manual lowering” to 8-10 seconds full up to full down.
10. Set “Automatic drop rate” slow enough to eliminate “hunting”.
11. Suggesting starting values are shown in the picture. • Your values may vary• See your Lexion Owner’s manual for more information
17
Operation
Operation
AHC Operation: All Combines
Operate the Headsight system exactly like you would use a Lexion system. Further details may be found in the combine operator’s manual.
1. Engage header and separator clutch (700 shown, 400-500 similar.)
2. Choose desired cutting height setpoints.• Lower the head to the desired cutting height
• Must be within the sensor travel range• Press and hold the “Left Side” button until the caret
resets to point to the top of the dark bar in the Left graph (Active Header Height)
• Tap button once and redo above to set 2nd position
• The greyed caret is selected• To set a higher feeder position, press and hold the
“Right Side” button until the caret resets to point to the top of the dark bar in the Right graph (feeder Position)
• Tap button once and redo above to set 2nd position
3. Press left side of header raise/lower button to enter active HHC. Press again to switch to 2nd setting.• The Left Side button (arrows to dot) is Active Header
Height (AHC). It should be used for all heads with height sensors on the head
• The Right Side button (arrows to lines) is “Feeder Position” (Return to Cut or RTC.) It should be used only for heads with NO height sensors, or to raise the head to a preset height for turning, etc.
18
Operation
Adjusting Float Pressure
The pressure changes fairly slowly. Hold the Increase or decrease button for 5-10 seconds to see if pressure changes.
1. To increase the pressure, press and hold the Increase Pressure button.
2. To decrease the pressure, press and hold the Decrease Pressure button.
3. The LED pressure indicator shows the approximate pressure in the float system. The green bar show the normal operating range of the header in flex mode.
• Running near the bottom of the green area means MORE ground pressure (less hydraulic pressure holding up the cutterbar)
• Use this area for dry, hard conditions
• Running near the top of the green area means LESS ground pressure (more hydraulic pressure holding up the cutterbar)
• Use this area for wet, soft conditions
• Raising the pressure all the way up should “lock up” the cutterbar for rigid mode
4. The Hydraflex heads are designed to run low. Set the Height point to about 15-25% of the height range, and use the pressure adjustment to keep the head from dragging up.
5. The LED pressure indicator can also show the deck plate position on a corn head if the header is equipped with a Headsight conversion and deck plate sensor.
Increase
Decrease
LED Pressure Indicator
19
Overview
Overview
Insight® Navigation
How to NavigateWhen in a menu (selection arrow appears to left side)
• Enter: chooses the selected menu choice• Esc: backs up one menu level• Up: moves up within the menu choices displayed • Down: moves down within the menu choices displayed
When in a screen which allows setting of parameters• Enter: backs up to last menu level AFTER saving• Esc: backs up to last menu level without saving• Up: increases the value• Down: decreases the value
Meaning of Status LightSolid Green:
• System is operating• No errors detected
Solid Red:• System is NOT operating• No height or tilt signals are sent to combine• You have changed settings which require calibration of Insight, are currently in a menu which will
force a calibration if you make any changes, or are in calibration mode
Solid Green with Flashing red:• System is operating• An error has been detected• Repair problem then clear errors
Flashing Red:• System is operating• A sensor has been ignored• See note in Troubleshooting by Error - ER16• Repair system - Recalibrate Insight
Screen Contrast AdjustmentTo increase contrast:
• Press and hold Esc +• Press Up to increase contrast (while holding Esc)
To decrease contrast:• Press and hold Esc +• Press Down to decrease contrast (while holding Esc)
20
Overview
Resetting Insight® to DefaultsTo reset all settings hold + for 5 seconds:
• Press and hold ESC then• Press and hold Enter while holding ESC• Hold both for 5 seconds
Updating Insight® Software with USB Drive
Updating software may cause the Foresight option to be disabled. If you have purchased Foresight, contact Headsight before updating software.
1. You will need:• USB drive• Means of loading USB Stick (computer with USB)
2. Load USB drive with new software files• Place insightf.hex in the root directory of USB drive (ex. E:\insightf.hex) • Do not change file names
3. If you do not have the new files you may• Download updated software from www.headsight.com • Order pre-loaded USB drive from Headsight, Inc.
4. Remove cap from USB on front of Insight controller
5. Insert USB drive card into USB slot on front of Insight
6. Power Insight• Turn on key switch
7. Wait for software to download• Yellow light will blink while download is in progress• Green light will turn on solid when download is complete
8. Verify update is successful• Go to >>About Insight>>Software Version and read software version number
9. Remove USB drive
10. Install cap on USB on front of Insight controller
11. Remove power from Insight• Turn off key
21
Advanced Info
Advanced Information
Theory of Operation
A review of the following points will help the service technician to understand the complete system which will help when diagnosing specific problems.
1. Each sensor returns a variable voltage depending on its height.• High height = high voltage (approximately 4 volts)• Low height = low voltage (approximately 1 volt)
2. Each sensor has 3 wires:• 5V power• Ground• Signal returned to the combine
• Varies between approximately 1.0 and 4.0 volts
3. The voltages the combine sees are exactly like what it would see with an OEM system. All existing combine controls and settings may be used.
Basic Requirements
If any sensor does not meet the requirements below you must correct it (to meet the requirements) and then recalibrate. See the header manual for sensor adjustment instructions. Each sensor must meet basic requirements for the combine to accept the calibration.
1. Signal must always be between .3 and 4.7 volts.
2. Signal must change more than 1.0 volts from raised to lowered position for each sensor.
22
Advanced Info
Reading Voltages
Before You Start
The Insight box can display both the input voltages it receives from each sensor and the output voltages it is sending to the combine.
Sensor voltage = Insight box input voltage Insight box output voltage = Combine sensor input
On the Insight® Box : Sensor Voltages1. From main menu, go to >>Diagnostics>>Disp Sensor
Voltages.• This shows real-time voltage coming from each sensor
2. For more information about sensor history and status see >>Diagnostics>>Detailed Diagnostics>>(parameter of interest.)
• Sensor = signal from sensor in volts• Max = the maximum voltage sent to Insight box from
sensor since last calibrated• Min = the minimum voltage sent to Insight box from sensor since last calibrated• Enabled = is this sensor enabled to control height? Yes or No• SetH = the “header raised” voltage set-point recorded during calibration• SetL = the “header lowered” voltage set-point recorded during calibration• Reversed = is the polarity of this sensor reversed? Yes or No
On the Insight® Box : Output Voltages
3. From main menu, go to >> Diagnostics>>Detailed Diagnostics>> (parameter of Interest). • This shows voltage being sent to the combine
4. Left or Right Height Out = X.XVolts:• 1V with head fully lowered• 4V with head raised
Insight box scales voltages received to what combine needs to function
Sensor Voltages
L LC CTR RC R0.0 0.0 0.0 0.0 0.0
Left Sens =0.00VMax=0.00V SetH=5.00VMin=0.00V SetL=0.00VEnabled=N Reversed=N
Pressure/aux Sensor Left Height OUTPUT Pressure Height OUT Right Height OUTPUT
Left Height OUTPUT
=2.0V
23
Advanced Info
Reading Voltages: Combine
1. You must have a Service Tool plugged into the Diagnostic ports to read voltages on a Lexion combine
2. To determine if the sensor voltages are getting to the combine, watch the Left bar graph on the display while raising and lowering the header. See the appropriate “Combine Settings” section for details.
12V Power Test
Complete the tests below to determine if you need to do the update. (Update should be very rare.)
1. Turn on engine. Make sure the Roading switch is in field mode.• If the Insight box turns on
• You do not need to install the power wire • Go to next section
• If the Insight box does not turn on• Make sure that Y401 on the adapter harness is
plugged into VS2. There should be 12V on the red wire in Y401 (pin 6)
• If not, then continue with step 2
2. Disconnect the Combine Multilink and use a voltmeter to measure pin 9 of the B housing on the Combine Multilink.• There is no 12V on pin B9
• Find and repair 12V supply problem on combine (most likely issue!)
• There is 12V on pin B9• Go to “12V Power Wire Install” in Advanced
Information. Install/repair the wiring on the header, or in the header multilink.
24
Advanced Info
600 & 700 Series Calibration Issues
Symptom: When the CAC system is engaged, the header dives into the ground, then recovers to the preset height.
Cause:For machines with 2011-2014 OEM Lexion software, play in the connection between the header and feeder house can cause the calibration process to not work correctly. If your feeder can drop more than ½" after the header solid frame (not flex cutterbar skids) touches the ground, it is recommended that you use one of the two following solutions.
Stubble stompers mounted so they contact the ground during calibration can also cause this issue.
Solutions:Solution 1–s/n C67, C68, C69
6/700 series combines with SN’s starting with C67, C68, or C69 and later should have the software updated to at least VBM 3.6.3 to eliminate this issue. For earlier machines, see solution 2.
Solution 2–Earlier Models
This procedure works for all 6/700 combines on all headers.
1. Remove or chain up any stubble stompers so they do not carry header weight during calibration.
2. Use blocks under the feeder faceplate to stop further movement downward during the calibration process. • The block height should be enough to stop the
feeder just as the solid frame of the head contacts the ground (not flex cutterbar skids). See arrows.
NOTE: Some heads with floating adapters (for example draper heads) can also experience this symptom in flex mode. Limiting downward over-travel on the float adapter during calibration (Solution 2 above) may solve or reduce this issue.
NOTE: For off-ground (rigid) operation, make sure float mode is locked out.
25
Advanced Info
12V Power Wire Installation
This step is not required for most headers. It should NOT be required on Headsight supplied Multilink assemblies. Complete the test below to determine if you need to do this step.
1. Make sure to do the test for combine power in Installation, 12V Power Test.• There is 12V on pin B9, AND• There is no 12V on VS2, pin 6, continue to step 2
2. Install Jumper or repair the wiring in the Header Multilink.
3. Turn off the engine.
4. Open the multilink assembly:• Remove any hoses or wiring in way of disassembly• Remove 5 socket head bolts from housing• Pull housing assembly away from face plate
5. Install the provided jumper for the 12V power source. • Snap insert 1 notch apart and Insert large pin to XB
pin 9, close insert. If there is already a pin, splice the wires
• Insert small pin to VS2 pin 6
26
Advanced Info
6. See pictures below for pin location.
7. Replace pin inserts in proper cavities of plate.
8. Reassemble the multilink assembly:• Reassembly of housing is easier if you remove the screws holding the VS1-3 plugs onto the
housing, and temporarily pull excess wiring out through the housing• Reassemble housing to plate, making absolutely sure no wires are pinched under the housing.
Wires like to get pinched in the “center” of the housing, and around the pin insert pegs• The housing should sit snug against the plate without drawing up the bolts• Install the 5 socket head bolts into housing• If removed, coil excess wiring back into housing and reinstall screws in VS1-3• Replace any hoses/harnesses removed for access
ID LABELOWNER HEADSIGHT, INC
ITEM SEE SHEET PART NUMBERREVISION SEE SHEET REV. #
DATE BUILD DATEMFG SUPPLIER NAME
2 TXL WIRE INSULATION MAY NOT EXCEED 0.078" (2MM) DIA.
1 LABEL EACH CONNECTOR WITH PART ID AND NAME
COMPONENT DATAITEM PART ID QTY DESCRIPTION MFG MFG PN TERMINAL PN ACCESSORY PN ACCESSORY PN
1 M1 1 MAIN FRAME- 500+ CLAAS 697 989 0
2 M2 1 ELECTRICAL HOUSING CLAAS 668 802 0
3 X A-C 3 CONTACT HOUSING CLAAS 214 185 0
4 M4 1 DUST CAP (NOT SHOWN) CLAAS 683 725 0
5 M5 1 DRAW BOLT CLAAS 683 722 1
6 M6 1 M12 NUT McMASTER 90591A181
7 M7 2 PLASTIC PLUGS, LARGE CLAAS 213 607 0
8 M8 5 CAP SCREWS, M5x40, SOCKET McMASTER 91290A258
9 M9 2 QR HYD. COUPLING CLAAS 668 810 0
10
11 M13 6 SCREW, #4x12" + FLAT, TYPE B McMASTER 90055A111
12
13
FRONT FACE VIEW
REAR FACE VIEW8
1
3
REAR VIEW
5
6
4
13
7
2
12
9
11
10
11
10
FRONT VIEW
8
3
1
12
9
2 4
13
7
5
6
XB XC
XA
XC XB
XA
STD VIEW SHOWN.PLUG IS ROTATED IN
HOUSING
VS2
REAR FACE VIEWWITH REAR CAP VS2
LIGHTSWIRES
VS3
VS3
VS1
SOLENOIDWIRES
TANKPRESSURE
VS1
M1
M2
M8 (x5)
M7 (x2)
M9 (x2)
XA-C (x3)
M6
M5
M13 (x6)
LABEL CONNECTOR VS2-HHC
LABEL CONNECTOR VS3-AP
LABEL CONNECTOR VS1
NOTES:
CA500MLHYD 6
4 CHANGED SOL. PLUG TO DTCH 2-14 JHK5 ADDED Y407 VALVE FUNCT. 3-16 JHK6 ADDED 12V, GND TO VS1 4-17 JHK
27
Advanced Info
Wiring and Diagrams
Header Adapter Harness
Y401
Y410
Y2408 Y112
Y424
Y150
HT9223 DP
Y101
Y502
Y414Y413
Y412Y411
Y248
Connector Description Connects toY502 31 pin Deutsch Header Connector – Header Single-PointY112 4 pin WP Multilink: Y111 Lights Y424 16 pin Amp CPC Adapter Feeder HarnessY101 24 pin DT Insight™ Control boxY150 12 pin DT Diode Module (HT9223 DP)Y408 12 pin DT Multilink: Y407 Valve FunctionsY401 7 pin C016 (AHC) Multilink: VS2Y410 7 pin CO16 (REEL) Multilink: VS1
Y411/2 2 pin DT set Reel Lift SolenoidsY413/4 2 pin DT set Reel F/A SolenoidsY538 1 pin WP Reel Select Harness
28
Advanced Info
Feeder Harness
Y534
Y423
Y225
Y231
Connector Description Connects toY423 16 pin AMP CPC Header Adapter HarnessY225 12 pin DT A code Hydraflex Cab Control Y534 2 pin WP Reel F/A Switch
29
Advanced Info
Reel Select Harness
Y534
Y540
Y539
Y541
Connector Description Connects toY539 1 pin WP Header Adapter HarnessY540 2 pin Deutsch plug Reel Select SolenoidY541 2 pin Receptacle OEM harness
30
Advanced Info
Multilink
Y407
Y517 Y518 Y111
VS1
VS3VS2
Connector Description Connects toVS1 Reel Sensors Y410 (If equipped)VS2 AHHC Y401VS3 AutoPilot Y409 (If equipped)Y111 Lights Y112Y517 Reel Drive Y518Y518 Reel Drive Y517Y407 Valve Functions Y408
31
Advanced Info
Header Adapter Schematic (Part 1)
001 SIGN
AL GN
D BLK
041 LEFT HG
T TAN
045 RIG
HT H
GT TAN
012 12V POW
ER R
ED
050 SENSO
R PW
R PN
K
100 SENSO
R G
ND
Lt BLU
087 RIG
HT SEN
SOR
WH
T
081 LEFT SENSO
R W
HT
Y101IN
SIGH
TP6
GR
OU
ND
P10LEFT H
GT SIG
P12R
IGH
T HG
T SIG
P412V PO
WER
P16BYPASS SIG
P19AU
X INPU
T
P2H
GT SN
S V+
P3H
GT SN
S GN
D
P9R
IGH
T HG
T
P7LEFT H
GT
Y401M
ULTI - VS2P01
GR
OU
ND
P03LEFT H
GT
P04R
IGH
T HG
T
P0612V PO
WER
Y502
HEADER
P20STUBBLE LTS
P15RT HZD LT
P16LEFT HZD LT
P05CHASSIS GND
P30FLEX PRESSURE
P27FLEX SELECT
P21REEL F/A
P08REEL VERT
P01REEL SPEED
P2512V POWER
P03SENSOR GND
P06SENSOR V+
P07SENSOR GND
P09RIGHT HGT
P10LEFT HGT
Y410M
ULTI - VS1P02
REEL SPEED
P03R
EEL VERT
P04D
ECK PLATE
032 RIG
HT H
AZARD
Dk G
RN
033 STUBBLE LTS BR
N
031 LEFT HAZAR
D YEL
022 CH
ASSIS GN
D BLK
098 REEL SPEED
GR
Y
113 REEL F/A YEL
112 REEL H
GT YEL
Y112LIG
HTS
AG
RO
UN
D
BLEFT H
ZD LT
CR
IGH
T HZD
LT
DSTU
BBLE LTS
PG4
POW
ERPG
4PO
WER
PG4
GR
OU
ND
PG4
CH
ASSIS GR
OU
ND
NO
TES:
QP0-C
A12-31A3
32
Advanced Info
Header Adapter Schematic (Part 2)
091
FLEX
PR
ESSU
RE
GR
Y
145
FLEX
-
BRN
079
FLEX
SEL
ECT
OR
G
001
SIG
NAL
GN
D B
LK
Y424
FLEX
CO
NTR
OL
P01
FLEX
PR
ESSU
RE
P02
FLEX
SEL
ECT
P03
FLEX
+
P04
FLEX
-
P05
GR
OU
ND
P06
POW
ER
P10
GR
OU
ND
P11
DR
APER
+
P12
DR
APER
+
P13
DR
APER
-
P14
DR
APER
-
144
FLE
X +
TAN
PG3
GR
OU
ND
012
12V
POW
ER R
EDPG
3PO
WER
078
REE
L SE
LEC
T P
UR
Y150
DIO
DE
PAC
KP1
SIG
NAL
P4R
EEL
+
P2VA
LVE
+
P6R
EEL
-
P9VA
LVE
-
P5R
EEL
SELE
CT
P7FL
EX -
P3FL
EX +
DIO
DE
PAC
K, R
EFER
ENC
E O
NLY
145
FLEX
-
BRN
144
FLE
X +
TAN
022
CH
ASSI
S G
ND
BLK
PG3
CH
ASSI
S G
RO
UN
D
Y408
VALV
E FU
NC
T. P12
GR
OU
ND
P09
REE
L FO
RE
P10
REE
L AF
T
P01
GR
OU
ND
P07
REE
L U
P
P08
REE
L D
OW
N
P02
MAS
TER
Y411
REE
L R
AISE
2SO
L +
1G
RO
UN
D
Y412
REE
L LO
WER
2SO
L +
1G
RO
UN
D
Y413
REE
L FO
RE
2SO
L +
1G
RO
UN
D
Y414
REE
L AF
T2
SOL
+
1G
RO
UN
D
142
REE
L FO
RE
OR
G
143
REE
L AF
T D
k BL
U
021
CH
ASSI
S G
ND
BLK
12" B
LK 1
8g
12" B
LK 1
8g
021
CH
ASSI
S G
ND
BLK
141
REE
L LO
WER
BR
N
140
REE
L R
AISE
WH
T
739
M S
OL
+ D
k G
RN
12"
18g
320
REE
L +
Lt B
LU
322
REE
L -
Lt G
RN
Y149
HT9
223-
DP1
0
P03
P02
P01
P04
P05
P06
P09
P08
P07
P11
P12
D6
D1
D2
D3
D4
D5
D7
D8
Y 5 0 2
H E A D E R
P14 REEL AFT
P13 REEL AFT
P12 REEL FORE
P11 REEL FORE
P27 FLEX SELECT
P30 FLEX PRESSURE
135
REE
L AF
T B
RN
16g
134
REE
L FO
RE
WH
T 1
6g
135
REE
L AF
T B
RN
16g
134
REE
L FO
RE
WH
T 1
6g
Y538
REE
L VA
LVE
AR
EEL
SELE
CT
NO
TES:
QP0
-CA1
2-31
A3
33
Advanced Info
Feeder Adapter Schematic:
012 12V POW
ER R
ED 16G
079 FLEX SELECT O
RG
020 CH
ASSIS GN
D BLK 16G
144 FLEX + TAN
091 FLEX PRESSU
RE G
RY
145 FLEX - BRN
Y225LIG
HTBAR
P01PR
ESSUR
E
P02FLEX SELEC
T
P03FLEX +
P04FLEX -
P05G
RO
UN
D
P0612V PO
WER
Y423FLEX C
ON
TRO
LP01
FLEX PRESSU
RE
P02FLEX SELEC
T
P03FLEX +
P04FLEX -
P05G
RO
UN
D
P06PO
WER
P11R
EEL FOR
E
P12R
EEL FOR
E
P13R
EEL AFT
P14R
EEL AFT
Y534R
EEL F/AA
DR
APER +
BD
RAPER
-135 R
EEL AFT BRN
12g
134 REEL FO
RE W
HT 12g
16g
NO
TES:
HT9870-FD
R2
USE W
ITH H
YDR
A & DYN
A FOR
LEXION
CO
MBIN
ES
34
Advanced Info
Multilink Diagram (Part 1)
031
LEFT
HZD
LT
YEL
12"
18g
032
RIG
HT
HZD
LT
Dk
GR
N 1
2" 1
8g
022
CH
ASSI
S G
ND
BLK
12"
18g
033
STU
BBLE
LTS
BR
N 1
2" 1
8g
Y518
12V
REE
LA
12V
POW
ER
VS2
HH
CP1
GR
OU
ND
P2H
HC
+5V
P3LE
FT S
NR
P4R
IGH
T SN
R
P612
V PO
WER
XAM
L, A
HO
USI
NG
P02
GR
OU
ND
P03
LEFT
HZD
LT
P06
RT
HZD
LT
P04
MAR
KER
LTS
P01
GR
OU
ND
P07
REE
L U
P
P08
REE
L D
OW
N
P09
REE
L FO
RE
P10
REE
L AF
T
P13
GR
OU
ND
XCM
L, C
HO
USI
NG
P12
GR
OU
ND
P01
HH
C S
NR
+5V
P02
HH
C L
EFT
SNR
P03
HH
C R
T SN
R
P04
DEC
K PL
ATE
P05
REE
L EN
ABLE
P08
AP S
NR
+5V
P09
AP S
NR
GN
D
P10
AP L
EFT
P11
AP R
IGH
T
Y517
REE
L EN
ABLE
AR
EEL
ENAB
LE
Y111
LIG
HTS
AG
RO
UN
D
BLE
FT H
ZD L
T
CR
T H
ZD L
T
DST
UBB
LE L
TS
VS3
AUTO
PIL
OT
P1AP
+5V
P2AP
GN
D
P3LE
FT S
NR
P4R
IGH
T SN
R
041
LEFT
HG
T T
AN 6
" 18g
045
RIG
HT
HG
T T
AN 6
" 18g
050
SEN
SOR
PW
R P
INK
6" 1
8g
750
SEN
SOR
PW
R P
INK
6" 1
8g
700
SEN
SOR
GN
D L
t BLU
6" 1
8g
781
CR
OP
1 L
WH
T 6
" 18g
[LEF
T SN
R]
782
CR
OP
2 R
WH
T 6
" 18g
[RIG
HT
SNR
]
138
REE
L EN
ABLE
PU
R 1
2" 1
8g
014
12V
POW
ER R
ED 8
" 18g
001
SIG
NAL
GN
D B
LK 6
" 18g
014
12V
POW
ER R
ED 1
2" 1
8g
M2
XBM
L, B
HO
USI
NG
P03
TABL
E FO
RE
P04
TABL
E AF
T
P05
UN
FOLD
P06
FOLD
P07
MAS
TER
P09
12V
POW
ER
P10
REE
L SP
EED
P11
REE
L VE
RT.
Pg5
12V
POW
ER
Pg5
SIG
NAL
GN
D
NO
TES:
CA5
00M
LHYD
6
35
Advanced Info
Multilink Diagram (Part 2)
VS1AU
X SNR
S
P1G
RO
UN
D
P2R
EEL SPEED
P3R
EEL HG
T
P4D
ECK PLATE
P612V PO
WER
XAM
L, A HO
USIN
GP02G
RO
UN
D
P03LEFT H
ZD LT
P06R
T HZD
LT
P04M
ARKER
LTS
P01G
RO
UN
D
P07R
EEL UP
P08R
EEL DO
WN
P09R
EEL FOR
E
P10R
EEL AFT
P13G
RO
UN
D
XCM
L, C H
OU
SINGP12
GR
OU
ND
P01H
HC
SNR
+5V
P02H
HC
LEFT SNR
P03H
HC
RT SN
R
P04D
ECK PLATE
P05R
EEL ENABLE
P08AP SN
R +5V
P09AP SN
R G
ND
P10AP LEFT
P11AP R
IGH
T
Y407VALVE FU
NC
T.P01
GR
OU
ND
P07R
EEL RAISE
P08R
EEL LOW
ER
P09R
EEL FOR
E
P10R
EEL AFT
P12G
RO
UN
D
P03TABLE FO
RE
P04TABLE AFT
P05U
NFO
LD
P06FO
LD
P02M
ASTER
098 REEL SPD
GR
Y 6" 18g
112 REEL H
GT YEL 6" 18g
111 DEC
K PLATE YEL/bk 6" 18g
142 REEL FO
RE O
RG
12" 18g
143 REEL AFT D
k BLU 12" 18g
021 CH
ASSIS GN
D BLK 12" 16g
140 REEL R
AISE WH
T 12" 18g
141 REEL LO
WER
BRN
12" 18g
021 CH
ASSIS GN
D BLK 12" 16g
M2
XBM
L, B HO
USIN
GP03TABLE FO
RE
P04TABLE AFT
P05U
NFO
LD
P06FO
LD
P07M
ASTER
P0912V PO
WER
P10R
EEL SPEED
P11R
EEL VERT.
158 UN
FOLD
WH
T/brn 14" 18g
159 FOLD
BRN
/wt 14" 18g
136 SWAP 1 O
RG
/bk 14" 18g
137 SWAP 2 D
k BLU/bk 14" 18g
739 M SO
L + Dk G
RN
14" 18g014 12V POW
ER R
ED 6" 18g
Pg412V PO
WER
Pg4SIG
NAL G
ND
001 SIGN
AL GN
D BLK 6" 18g
NO
TES:
CA500M
LHYD
6
36
Diagnostics
Header Multilink Mechanical
ID L
ABEL
OW
NER
HEA
DSI
GH
T, IN
CIT
EMSE
E SH
EET
PAR
T N
UM
BER
REV
ISIO
NSE
E SH
EET
REV
. #D
ATE
BUIL
D D
ATE
MFG
SUPP
LIER
NAM
E
2TX
L W
IRE
INSU
LATI
ON
MAY
NO
T EX
CEE
D 0
.078
" (2M
M) D
IA.
1LA
BEL
EAC
H C
ON
NEC
TOR
WIT
H P
ART
ID A
ND
NAM
E
CO
MPO
NEN
T D
ATA
ITEM
PAR
T ID
QTY
DES
CR
IPTI
ON
MFG
MFG
PN
TER
MIN
AL P
NAC
CES
SOR
Y PN
ACC
ESSO
RY
PN
1M
11
MAI
N F
RAM
E- 5
00+
CLA
AS69
7 98
9 0
2M
21
ELEC
TRIC
AL H
OU
SIN
GC
LAAS
668
802
0
3X
A-C
3C
ON
TAC
T H
OU
SIN
GC
LAAS
214
185
0
4M
41
DU
ST C
AP (N
OT
SHO
WN
)C
LAAS
683
725
0
5M
51
DR
AW B
OLT
CLA
AS68
3 72
2 1
6M
61
M12
NU
TM
cMAS
TER
9059
1A18
1
7M
72
PLAS
TIC
PLU
GS,
LAR
GE
CLA
AS21
3 60
7 0
8M
85
CAP
SC
REW
S, M
5x40
, SO
CKE
TM
cMAS
TER
9129
0A25
8
9M
92
QR
HYD
. CO
UPL
ING
CLA
AS66
8 81
0 0
10 11M
136
SCR
EW, #
4x1 2"
+ F
LAT,
TYP
E B
McM
ASTE
R90
055A
111
12 13
FRO
NT
FAC
E VI
EW
REA
R F
ACE
VIEW
8 1 3
REA
R V
IEW
56
4
137
2 129
1110
1110
FRO
NT
VIEW
8 31
129
24
137
56
XBXC
XA
XCXB
XA
STD
VIE
W S
HO
WN
.PL
UG
IS R
OTA
TED
INH
OU
SIN
G
VS2
REA
R F
ACE
VIEW
WIT
H R
EAR
CAP
VS2
LIG
HTS
WIR
ES
VS3
VS3
VS1
SOLE
NO
IDW
IRES
TAN
KPR
ESSU
RE
VS1
M1
M2
M8
(x5)
M7
(x2)
M9
(x2)
XA-C
(x3)
M6
M5
M13
(x6)
LABE
L C
ON
NEC
TOR
VS2
-HH
C
LABE
L C
ON
NEC
TOR
VS3
-AP
LABE
L C
ON
NEC
TOR
VS1
NO
TES:
CA5
00M
LHYD
6
4C
HAN
GED
SO
L. P
LUG
TO
DTC
H2-
14JH
K5
ADD
ED Y
407
VALV
E FU
NC
T.3-
16JH
K6
ADD
ED 1
2V, G
ND
TO
VS1
4-17
JHK
37
Diagnostics
Reel Select Schematic:
078 REEL SELEC
T Dk BLU
Y539TO
Y538A
REEL SELEC
T
Y540R
EEL VALVEP1
REEL SELEC
T
P2G
RO
UN
D
Y541O
EM H
ARN
ESSP1
REEL SELEC
T
P2G
RO
UN
D
001 SIGN
AL GN
D BLK
NO
TES:
HT9863-R
S2
38
Diagnostics
Diagnostics
Troubleshooting by Symptom
Nearly every problem with the header control system on CIH combines may be resolved by one of the following simple steps:
• Make sure each sensor meets basic requirements discussed in Advanced Info section• Properly calibrate Insight box• Properly calibrate combine• Enable appropriate HHC functions• Properly set combine electronics and/or hydraulics
Symptom Problem SolutionHeader is too jumpy or responds too slowly
Calibration not properly completed
Recalibrate Insight box and combine
Combine improperly set See Combine Settings Section
4/500 Decrease Fast Drop 6/700 Reduce Auto Drop rateAdjust sensitivity
Pressure Bypass installed when not needed.
See Installation/Pressure Bypass Harness
Combine Header Cal Fails
(Cutting Height Limits) or(Learning End stops)
Header not properly connected Verify that Insight harness is attached to VS2, and Insight box has power.
Insight not Setup & Calibrated or has Errors
Do initial Setup and Calibration
Repair error, clear error codes Cycle keyRecalibrate Insight
Insight Outputs are not correct
>>Diagnostics>>Detailed Diagnostics>>Left/Right Height Output
0.8-1.2V head fully lowered 3.8-4.2V sensors off ground
Recalibrate Insight on flat surface.
Reset Insight: See Insight Overview for details
Insight defective
Combine computer needs to be reset (4/500 Series only)
Disconnect header Multilink with key on, motor running.
Turn off key/motor.Reconnect Header
Turn on key, start engine.
39
Diagnostics
Symptom Problem SolutionLift Pressure Sensor Error in combine(4/500 Series only)
Pressure Bypass Jumper not installed
Install jumper for headers w/o Insight box
Cannot operate head low enough Calibration not properly completed
Perform Insight and Combine calibration on flat level surface
Contact Headsight regarding optional products Foresight and/or Feathersight
Cannot operate head high enough
Calibration not properly completed
Perform Insight and Combine calibration on flat level surface
Install extensions on corn sensors
Header works upward, then dives to ground (4/500 Series only)
Slow Lower non-functional Test combine manual slow lower mode.
Turn OFF Thresher & HeaderTest slow raise/lower modes.Head should raise and lower slowly. If not, repair OEM header lift valve assm.
Header dives to ground and recovers entering crop
Lower Rate set too high See Combine Specific Settings
6/700 Series: To much play in feeder to header coupling
(Due to a quirk in early combine SW, calibration does not work correctly with too much play)
Combine SN’s starting with C67, C68, or C69Update combine to VBM 3.6.3 or above.
All others:Block front of feeder so feeder cannot continue down after Header frame touches the ground.
40
Diagnostics
Symptom Problem SolutionNo Automatic operation Wiring not connected, or
calibration not completed.See Installation/ Calibration/ Settings sections of manual
Header control not enabled See Operation section
Insight box settings or calibrations incorrect
Verify that the proper combine and header type have been selected. Redo “Perform Calibration” on Insight box
Power supply from combine less than 10V to Insight
Roading switch on, Turn to field mode. Test pin B9 at the combine Multilink for 12V.
Insight box needs to be reset See Insight Overview for detailsInsight box/wiring failure >>Diagnostics>>Detailed
Diagnostics>>Left/Right Height Output0.8-1.2V head fully lowered3.8-4.2V sensors off ground
Combine Problem Contact your Lexion Service Center.
Height works but not Tilt Increase Tilt Sensitivity. >>Setup>>Tilt SensitivityIncrease Tilt sensitivityPress Check
Rare combine problem Call Headsight to increase Max Combine Tilt.
Head rocks back and forth Tilt Sensitivity too high Adjust sensitivity in combine
On Insight: >>Setup>>Tilt Sensitivity
Decrease Tilt sensitivityPress Check
Insight/Combine not calibrated properly(Do Cal on flat surface)
See Installation/ Calibration/ Settings sections of manual
Header tips wrong way(Once head is moved off level, it continues all the way in either direction)
Left and Right sensors reversed Adapter Harness Mis-wiredContact Headsight
41
Diagnostics
Symptom Problem SolutionHead tips all the way one direction
Sensor or wiring fault on head(Error on Insight)
Correct fault on head. Contact JD Service
Poor connection Check harness and connectors for cut/torn wire, loose, or “pushed back” terminals
Insight Miscalibration or Fault See Diagnostics>>Detailed Diagnostics>>Left (Right) Height Output. Output Voltages should read about the same with head level. If not, recalibrate
Adapter Harness fault Contact Lexion Service to read voltages in combine. Voltages should read the same as above. If not, trace wiring from Insight through Multilink
Header runs slightly out of level Insight or Combine not calibrated correctly
Perform Insight Cal and combine Header Cal. on flat surface
Header not adjusted correctly Make sure the frame to cutterbar adjustment is the same across the width of the head
Lower and tilt head until cutterbar skids just touch on a flat surface.Make sure frame is level to ground within 1” from left to right. Readjust head if necessary.
All the above fails to correct problem:
>>Settings>>Tilt BalanceAdjust balance to level Head (must be reset to 100 before calibrating combine)
Display dim, blank, or hard to read
Screen contrast improperly adjusted
See Insight Settings
Weak power supply to Insight™ box
See 12V Power Test
Short in sensors powered by Insight box
Reversed polarity to hall-effect sensors may cause this symptom Individually disconnect sensors to isolate problem – screen will regain contrast when faulty sensor is disconnected. Correct short in wiring. Insight will need reset after correction of wiring short
Control box failure Contact Headsight
42
Diagnostics
Symptom Problem SolutionReel does not Raise or Lower Wiring not connected properly
Diode Module Not installed or is defective
Diverter valve on head not replaced with NC valve, or HT9862-RS harness not installed
Hydraulic problem on head
Verify that Y423 & Y424 are connected at header to feeder
Verify Y407 & Y408 are connected
Verify Y411 & Y412 are connected to the correct solenoids
Verify that HT9223 module is installed on Y150
Verify that Y538 has 12V when either Reel raise or lower is pressed.
Check for 12V at Reel Diverter valve when either Reel raise or lower is pressed. NC solenoid must be installed.
Check hoses for correct connection pattern
Contact HeadsightFlex Controller does not light up Power not connected.
Plug not seated
No 12V to Y225
No Ground to Y225
Defective control
Check power adapter connection to 12V & groundConnect Y569,Y570
Make sure Y225 fully seated in Hydraflex control
Check pin 6 (red wire)
Check pin 5 (black wire)
Call Headsight.Flex pressure does not Increase with button.
(Pressure can increase by pressing Reel Raise and Flex increase simultaneously)
Master Valve not firing Verify Y408 pin 2 is 12V when either pressure up or down is pressed.
Make sure the HT9223 module is installed on Y150
Reel/Flex Diagnostics
43
Diagnostics
Symptom Problem SolutionFlex pressure does not Increase or decrease.
(Cutterbar does not physically change weight if button held for > 1 minute.)
Wiring not connected properly
Diode Module Not installed
Plug not seated
Diverter valve on head not firing
Check for 12V at Flex Diverter valve.
Hydraulic problem on head
Defective control
Verify that Y423 & Y424 are connected at header to feeder
Verify Y407 & Y408 are connected
Verify Y411 & Y412 are connected to the correct solenoids
Verify that HT9223 module is installed on Y150
Make sure Y225 fully seated in Hydraflex control
Verify that Pin 27 of Y502 has 12V when either Flex Increase or Decrease is pressed.
Test header harness
Check hoses for correct connection pattern
Contact AGCO service
Call Headsight.Flex pressure bar graph does not Increase or decrease.
(Cutterbar does physically change weight if button held for > 1 minute.)
Defective Shift Module
Defective Pressure sensor
Wiring on header bad
Defective wiring in Headsight system
Y225 not fully connected
Defective display
Temporarily remove module and reconnect OEM harness to sensor. If display works, replace module
Test/Replace sensor on header—See AGCO Service
Test/Replace wiring on header—See AGCO Service
Trace/repair wire from Y502, pin 30 to Y225, pin 1. See attached Schematics.
Make sure Y225 is fully seated
Call Headsight
44
Diagnostics
Troubleshooting by Insight® Error Codes
Error Code Problem SolutionER11
Left sensor signal less than 0.3VLeft sensor temporarily disconnected.
Wiring open
Sensor failure
Repair wiring or bad connectorCalibrate Insight BoxCalibrate Combine
Check sensor harness for pinched/broken wiring
See sensor test instructionsER12
Left sensor signal greater than 4.7V
Wiring problem
Sensor failure
Ground wire to sensor is openSignal short to powerCalibrate Insight BoxCalibrate Combine
See sensor test instructionsER13
Left sensor swing less than 0.6VLeft sensor mechanical range is restricted
Sensor failure
Verify sensor is not obstructed in swingVerify sensor can collapse fully with header loweredAdjust down stop to allow greater range
See sensor test instructionsER16
Left sensor expected but not detected
Left sensor not properly connected
Not enough swing during cal
Incorrect number of sensors selected in setup
Sensor failure
Control box /wiring failure
Verify harness is connected to sensor 1Verify harness is connected properly to control box harnessVerify that signal wire (Pin B white wire of sensor cable) is connected to PIN7 of connector Y101 (Insight box)
Make sure sensor meets requirements in - Advanced Information - Basic Requirements section of this manual
Go to >>Initial Setup>>Number Sensors and choose the correct number of sensors
See sensor troubleshooting instructions
Contact Headsight
45
Diagnostics
Error Code Problem SolutionER17
Left sensor detected but not expected
Incorrect number of sensors selected in setup
Harness wiring error
Control box /wiring failure
Go to >>Setup>>System Select and choose the correct number of sensors
Verify that no wires contact PIN7 of connector Y101
Contact HeadsightER21
Left Center sensor signal less than 0.3V
Left Center sensor temporarily disconnected.
Wiring open
Sensor failure
Repair wiring or bad connectorCalibrate Insight BoxCalibrate Combine
Check sensor harness for pinched/broken wiring
See sensor test instructionsER22
Left Center sensor signal greater than 4.7V
Wiring problem
Sensor failure
Ground wire to sensor is openSignal short to powerCalibrate Insight BoxCalibrate Combine
See sensor test instructionsER23
Left Center sensor swing less than 0.6V
Left Center sensor mechanical range is restricted
Sensor failure
Verify sensor is not obstructed in swingVerify sensor can collapse fully with header loweredAdjust down stop to allow greater range
See sensor test instructions
46
Diagnostics
Error Code Problem SolutionER26
Left Center sensor expected but not detected
Left Center sensor not properly connected
Not enough swing during cal
Incorrect number of sensors selected in setup
Sensor failure
Control box /wiring failure
Verify harness is connected to left center sensorVerify harness is connected properly to control box harnessVerify that signal wire (Pin B white wire of sensor cable) is connected to PIN13 of connector Y101 (Insight box)
Make sure sensor meets requirements in - Advanced Information - Basic Requirements section of this manual
Go to >>Initial Setup>>Number Sensors and choose the correct number of sensors
See sensor troubleshooting instructions
Contact Headsight
ER27Left Center sensor detected but
not expected
Incorrect number of sensors selected in setup
Harness wiring error
Control box /wiring failure
Go to >>Setup>>System Select and choose the correct number of sensors
Verify that no wires contact PIN13 of connector Y101
Contact HeadsightER31
Center sensor signal less than 0.3V
Center sensor temporarily disconnected.
Wiring open
Sensor failure
Repair wiring or bad connectorCalibrate Insight BoxCalibrate Combine
Check sensor harness for pinched/broken wiring
See sensor test instructionsER32
Center sensor signal greater than 4.7V
Wiring problem
Sensor failure
Ground wire to sensor is openSignal short to powerCalibrate Insight BoxCalibrate Combine
See sensor test instructions
47
Diagnostics
Error Code Problem SolutionER33
Center sensor swing less than 0.6V
Center sensor mechanical range is restricted
Sensor failure
Verify sensor is not obstructed in swingVerify sensor can collapse fully with header loweredAdjust down stop to allow greater range
See sensor test instructionsER36
Center sensor expected but not detected
Center sensor not properly connected
Not enough swing during cal
Incorrect number of sensors selected in setup
Sensor failure
Control box /wiring failure
Verify harness is connected to center sensorVerify harness is connected properly to control box harnessVerify that signal wire (Pin B white wire of sensor cable) is connected to PIN8 of connector Y101 (Insight box)
Make sure sensor meets requirements in - Advanced Information - Basic Requirements section of this manual
Go to >>Initial Setup>>Number Sensors and choose the correct number of sensors
See sensor troubleshooting instructions
Contact HeadsightER37
Center sensor detected but not expected
Incorrect number of sensors selected in setup
Harness wiring error
Control box /wiring failure
Go to >>Setup>>System Select and choose the correct number of sensors
Verify that no wires contact PIN8 of connector Y101
Contact HeadsightER41
Right Center sensor signal less than 0.3V
Right Center sensor temporarily disconnected.
Wiring open
Sensor failure
Repair wiring or bad connectorCalibrate Insight BoxCalibrate Combine
Check sensor harness for pinched/broken wiring
See sensor test instructions
48
Diagnostics
Error Code Problem SolutionER42
Right Center sensor signal greater than 4.7V
Wiring problem
Sensor failure
Ground wire to sensor is openSignal short to powerCalibrate Insight BoxCalibrate Combine
See sensor test instructionsER43
Right Center sensor swing less than 0.6V
Right Center sensor mechanical range is restricted
Sensor failure
Verify sensor is not obstructed in swingVerify sensor can collapse fully with header loweredAdjust down stop to allow greater range
See sensor test instructionsER46
Right Center sensor expected but not detected
Right Center sensor not properly connected
Not enough swing during cal
Incorrect number of sensors selected in setup
Sensor failure
Control box /wiring failure
Verify harness is connected to right center sensor Verify harness is connected properly to control box harnessVerify that signal wire (Pin B white wire of sensor cable) is connected to PIN14 of connector Y101 (Insight box)
Make sure sensor meets requirements in - Advanced Information - Basic Requirements section of this manual
Go to >>Initial Setup>>Number Sensors and choose the correct number of sensors
See sensor troubleshooting instructions
Contact Headsight
ER47Right Center sensor detected but
not expected
Incorrect number of sensors selected in setup
Harness wiring error
Control box /wiring failure
Go to >>Setup>>System Select and choose the correct number of sensors
Verify that no wires contact PIN14 of connector Y101
Contact Headsight
49
Diagnostics
Error Code Problem SolutionER51
Right sensor signal less than 0.3V
Left sensor temporarily disconnected.
Wiring open
Sensor failure
Repair wiring or bad connectorCalibrate Insight BoxCalibrate Combine
Check sensor harness for pinched/broken wiring
See sensor test instructionsER52
Right sensor signal greater than 4.7V
Wiring problem
Sensor failure
Ground wire to sensor is openSignal short to powerCalibrate Insight BoxCalibrate Combine
See sensor test instructionsER53
Right sensor swing less than 0.6V
Right sensor mechanical range is restricted
Sensor failure
Verify sensor is not obstructed in swingVerify sensor can collapse fully with header loweredAdjust down stop to allow greater range
See sensor test instructionsER56
Right sensor expected but not detected
Right sensor not properly connected
Not enough swing during cal
Incorrect number of sensors selected in setup
Sensor failure
Control box /wiring failure
Verify harness is connected to right sensor Verify harness is connected properly to control box harnessVerify that signal wire (Pin B white wire of sensor cable) is connected to PIN9 of connector Y101 (Insight box)
Make sure sensor meets requirements in - Advanced Information - Basic Requirements section of this manual
Go to >>Initial Setup>>Number Sensors and choose the correct number of sensors
See sensor troubleshooting instructions
Contact Headsight
50
Diagnostics
Error Code Problem SolutionER57
Right sensor detected but not expected
Incorrect number of sensors selected in setup
Harness wiring error
Control box /wiring failure
Go to >>Setup>>System Select and choose the correct number of sensors
Verify that no wires contact PIN9 of connector Y101
Contact HeadsightER61
Sensor 6 (aux sensor) signal less than 0.3V
Wiring open
Sensor failure
Check sensor harness for pinched/broken wiring
See sensor test instructionsER62
Sensor 6 (aux sensor) signal greater than 4.7V
Wiring problem
Sensor failure
Ground wire to sensor is open
See sensor test instructionsER92
Tilt Sensitivity greater than 4.0VWiring problem
Turn the Tilt sensitivity knob in the cab to Maximum CW. Read under >>Diagnostics>>Detailed Diag.>>Tilt Sens In, on the Insight boxReading between 4.0 and 4.5. Call Headsight for instructions
Reading > 4.5V, Combine problem- Check wiring on combine
51
Parts
Parts
ITEM QTY. PART NUMBER DESCRIPTION1 1 QP0-CA12-31A Header Adapter Harness2 1 HT9870-FDR Feeder Harness3 1 INSIGHT AHC Interface4 1 HT9993 Hydraflex Cab Control5 1 CA500MLHYD Multilink Assm.6 1 HT9219 Pressure Shift Module7 1 HT9300 Power Adapter (not shown)8 1 08100147 Valve Insert, N.C. (not shown)9 1 HT9863-RS Reel Select harness (not
shown)10 1 HT2259 Clip, Header plugs (not
shown)
3
5 9
2
5
4
1
6
52
STATEMENT OF LIMITED WARRANTY
For Headsight® Products Headsight Inc. (Headsight) warrants its new products to be free from defects in material and workmanship for a period of twelve (12) consecutive months following the date of purchase by the retail purchaser.
Headsight Inc. (Headsight) warrants its new corn sensors assemblies for a period of thirty-six (36) months.
Headsight warrants genuine Headsight replacement parts and components to be free from defects in material and workmanship for a period of six (6) consecutive months following the date of purchase or the remainder of the original equipment warranty period, whichever is longer.
Headsight’s obligation under these warranties shall be limited to repairing or replacing, free of charge to the original purchaser, any part that, in Headsight’s judgment, shows evidence of such defect.
Limitations to Warranty
This warranty does not cover:• Warranty claims directly resulting from improper installation of the product.• Any product damaged by accident, abuse, misuse, or negligence after shipment from Headsight.• Any unauthorized product alteration or modification.• Any unauthorized repairs made with parts other than genuine Headsight parts.• Any repairs performed by anyone other than Headsight or an authorized Headsight dealer unless specifically authorized
by Headsight.
Warranty Procedure• Troubleshooting should be done between farmer/dealer and Headsight through our technical assistance @
574.220.5511. • Labor reimbursement will occur only pre-arranged through Headsight technical assistance and be scheduled to a flat rate
basis or reasonable time allowance in Headsight’s judgment. • There is no mileage reimbursement. • Diagnostic time will not be reimbursed except in pre-arranged circumstances.• Warranty claims should be on typical dealer service work order with a number and name to be attached for any future
correspondence. • All warranty work must be performed, and claims submitted, within thirty (30) days of the occurrence of the claim and
within the warranty period.• All parts removed during warranty repair must be returned to Headsight with Headsight’s Return Form within thirty (30)
days of the occurrence of the claim and within the warranty period.• Headsight, Inc. reserves the right to either inspect the product at the original retail purchaser’s location or require it to be
returned to Headsight, Inc. for inspection.
Limitation of LiabilityHeadsight makes no express warranties other than those, which are specifically described herein. Any description of the goods sold hereunder, including any reference to buyer’s specifications and any descriptions in circulars and other written material published by Headsight is for the sole purpose of identifying such goods and shall not create an express warranty that the goods shall conform to such description.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED. There are no implied warranties of merchantability or fitness of a particular purpose. This warranty states Headsight’s entire and exclusive liability and buyer’s exclusive remedy or any claim for damages in connection with the sale of furnishing of Headsight products, their design, suitability for use, installation or operation, or for any claimed defects herein. HEADSIGHT WILL IN NO EVENT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES WHATSOEVER, NOR FOR ANY SUM IN EXCESS OF THE PRICE RE-CEIVED FOR THE GOODS FOR WHICH LIABILITY IS CLAIMED.
No representative of Headsight nor any dealer associated with Headsight has the authority to change the items of this warranty in any manner whatsoever, and no assistance to purchaser by Headsight in the repair of operation of any Headsight product shall constitute a waiver of the conditions of this warranty, nor shall such assistance extend or revive it.
Headsight reserves the right to make improvements in design or changes in specifications at any time, without incurring any obligation to owners of units previously sold. Warranty: 1/2017
P 574.546.5022 • F 574.546.57604845 3B Rd • Bremen, IN [email protected]